Wall structure



wFuy 20, i937. A. J. MEIER WALL .STRUCTURE Original Filed April 16, 1923 5 Sheets-Sheet 1 We s A. J. MEIER WALL. STRUCTURE July 20, 1937.

v5 Sheets-sheet 2 Original Filed April 16, 1925 July 2o, 1937.

A. J. MElER 2,087,523

WALL STRUCTURE Original Filed April 16, 1923 5 Sheets-Sheet 3 ALBERT d. M75/a,

A. J. MEIER WALL STRUCTURE July 20, 1937.

5 sheets-smet 4 Original Filed April 16, 1925 @Aww/E00' /94 aff? r d. /VE/Ef?,

July 20, 1937.

A. J. MEIR 2,087,523

WALL STRUCTURE Original Filed April 16, 1923 5 Sheets-Sheet 5 Hwa/er d /VE/E,

Patented July 20, 1937 UNITED .STATES WALL STRUCTURE Albert J. Meier, New York, N. Y., assigner, by

mesne assignments, to Rockwood Gypsum Corporation of America, St. Louis, Mo., a corporation of Nevada Original 'application April 16, 4192,3, Serial No. 632,425. Divided and this application May 14, 1937, Serial No. 142,636

7 Claims.

This invention relates to building construction and more particularly to wall construction as carried out by means of timbers artificially manufactured by casting out of lithlc material.

In accordance with the present invention the material used for the manufacture of this timber is gypsum in the calcined form which, after being mixed with water, may be poured into molds y in a manner similar to the manufacture of reenforced concrete structures or the like. Gypsum in this or similar forms has been used for casting various shapes, such as small Statuary and ornaments of various kinds. This material is also cheap and easy to handle. It is not strong enough, however, to lend itself readily to structural purposes in the same way as cement concrete which may be reenforced by steel in those parts which are subjected to tensile stresses.

One of the objects of this invention is to provide a building structure in which the elements are of cast gypsum.

Another object of this invention is to provide a method of assembling timbers in a building structure in such a waythat they will be adequately supported and incorporated with the structure.

Further objects will appear from the detail description taken in connection with the accompanying drawings, in which:

Figures 1 to '7 inclusive are views illustrating forms of timber used in wall structures embodying this invention;

Figure 8 is a horizontal sectional view showing l one form of single wall structure embodying this invention;

Figure 9 is a section on line 9-9 of Figure 8;

Figure 10 is a horizontal section showing another form of single wall structure embodying this invention;

Figure 11 is a section on line H--Il of Figure 10;

Figure 12 is a horizontal section showing one form of double wall structure embodying this invention;

Figure 13 is a section on line I3-l3 of Figure l2;

Figure 14 is a horizontal section showing another form of double wall construction embodying this invention;

Figure 15 is a, section on line |5'l5 of Figure 14;

Figure 16' is a horizontal section showing a structure for enclosing a steel column or the like;

Figure 17 is a perspective view showing the general plan of building construction in accordance with this invention; and

Figure 18 is a perspective view showing a portion of a double wall constructed in accordance with this invention.

vThis application is a division of application, Serial No. 632,425, led April 16, 1923. While the general construction is described in this application, only those novel features pertaining to wall structure are claimed herein, other features being claimed in the parent application. This ap plication is a substitute for application Serial Number 503,251, filed December 18, 1930, allowed November 22, 1935 (which became forfeited by failure to pay the nal fee), Which latter application was also a division of application Serial Number 632,425. y

In accordance with this invention, a timber is provided, formed of cast gypsum. This is so constructed that a hollow building structure timber of cast gypsum is provided which is characterized by the feature that it has a length which is large compared to its transverse dimension, but is of suflicient rigidity and strength to carry a load when supported at its ends. It, therefore, distinguishes from building blocks and the like, which are not timbers. This timber preferably has incorporated therein and with the gypsum, a suitable binder, such as bagasse, although other fibrous binders, such as cut rope or wood chips may be used. The timber may also be suitably reinforced with rods, bars or other elements such as are employed in the reinforcement of concrete generally.

In practice, where a binder, such as bagasse, is used, the binder, in the proportion of to of the total mass, and in shredded form and short lengths' of the size of hogs hair, is mixed with the water in order to form a thick soupy mixture. To this is then added the calcined gypsum, and the whole is cast in a suitable form or mold.

The timber when used for a wall is formed to provide one or more cavities or cells therealong,

and it may be formed to provide a tongue anda groove therealong. The timber may also be provided with channels or other means in order to provide a plaster-receiving and retaining face. When erected in a wall, certain of the cavities may be lled with concrete, suitably reinforced, in order to provide supporting means for the Wall.

Where the timber is to form a floor or other load bearing part, it is constructed to receive concrete in order to provide a beam. Accordingly the timber is formed to provide a channel adapted to receive concrete, suitably reinforced; and in order to provide for shipment the timber has a series of cavities therealong, the wall of one of which may be broken open to provide a channel.

Referring to the accompanying drawings, Figures 1 to 'l inclusive, illustrate some of the various forms of timbers which may be used in wall structures in accordance with this invention. Figure 17 gives an idea of the general plan of the building structure as a whole.

'I'he wall timbers I I may be formed as illustrated in Figures 1 to 7 inclusive. 'I'hese are cast in a substantially rectangular form in cross-section having a cavity I2 as illustrated in Figure 1 or a number of cavities as illustrated in Figure 2, according to the service for which the unit is intended. One side oi' the timber is provided with a. tongue I3 and the opposite side with a groove I4 so that the adjoining timbers may be interlocked by engagement of tongues and grooves in a well known manner. One or both faces of the timber may be provided with transverse grooves I5 for the engagement of plaster or other suitable facing to be applied to the wall as a finish.

rIn casting these timbers, a. suitable paper facing I6 may be placed in the moldso that the finished timber will be provided with a reenforcingfacing of paper, fabric orother fibrous material which will" not only assist in reenforcing the surface but.

will also provide a surface to which materials used for finishing will adhere. It is, of course, immaterial whether the paper be inserted in the mold and attached to the surface during the casting operation or the castingbe completed first and the facing applied afterward. Figure 4 shows the facing lapplied to two opposite sides of the timber. In Figure 5 the facing is carried completely around the timber and in Figure 6 a facing Il is also applied to the interior surface of the cavity I2.

In Figures 8 to l1 inclusive are illustrated methods of constructing the wall in accordance with this invention. In Figures 10 and 11 timbers having a plurality of cavities, such as illustrated in Figure 2, are used. In Figures 8 and 9 timbers having a single cavity are used. In these figures the wall has a thickness of only a single timber. As will be seen from these figures the timbers I I are placed up-right on a suitable foundation and in adjoining relation with one another, the tongues I3 of one timber engaging the grooves I4 in the adjoining one; in practice the tongues and grooves will be so smooth as to form a sufllciently tight joint, however, if desired a layer of mortar may be provided to complete the joint. These timbers are in practice long enough to complete the wall between two floors, however, shorter lengths may be placed, one upon the other in vertical sections so that the cavities of all those in a vertical stack will register with one another. When a suitable height of wall has been built up, certain selected cavities have inserted therein one or more reenforcing members I8 which may be steel rods such as are ordinarily used in reenforced concrete constructions. When these reenforcing members have been suitably positioned in the cavities, these cavities are filled with concrete so as to form columns adapted to provide supports for the fioors and also to stiffen the wall structure.

When the wall has been built any desired facing may be applied to the outer surface thereof. In Figures 10 and 11 this facing is shown in the form of brick or tile I9 held in place by a suitable mortar 20. Figure 11 shows a section on line II-II of Figure 10. In Figure 8 the facing is shown as a layer 2| of plastic material, such as walls are built in the manner illustrated in FigureA 10 but omitting the tile facing of Figure 10, and these walls are spaced a short distance from one another so as to leave an air space 22 between the inner and outer walls. In this case as before, the reenforcements I8 and the concrete fillings 23 4are provided in certain of the timber cavities to reenforce the wall and provide supporting columns for the floors. Any outer facing 2i may be applied as previously described.

In Figures 14, l5 and 16 a double wall construction using the multi-cavity timbers similar` to Figure 2 is shown but a somewhat different construction is used in this case. In this construction special timbers 24 of modified form are provided as headers adapted to bond together the rows of timbers II used as stretchers. Corner timbers 25 of special form are also provided. In this case the reenforcements IB and the concrete fillings 23 are'applied to the headers 24 and the comer timbers 25. 'I'his construction, therefore, provides a heavy column of concrete at each corner and stout reenforced columns at regular intervals along the wall. The air spaces 22 between the inner and outer walls are broken up by the headers 24 so as to prevent too free a circulation of air therein. Figure l5 is ay section on line I5-'I5, Figure 14.

In Figure 16 a construction is shown wherein a steel column may be enclosed by timbers in accordance with this invention. In this figure the column may be constructed, for instance, of a pair ofsteel channels 26 connected by plates 21. The columns so constructed may be enclosed by four timbers 2l and 29, of special form as shown. In this case certain cavities may also receive a filling of concrete for stiffening but this is ordinarily not necessary.

The construction of a building in accordance with this invention is illustrated in Figure 17, In this construction the walls are first erected by setting up timbers II in adjoining relation, as previously described, on a suitable foundation. When a sufficient height of wall has been built up, reenforcements I8 are inserted and the corresponding cavities filled with concrete as previously described. 'I'his provides a series of reenforced concrete columns at regular intervals along the wall. The floors may then be laid /on by placing timbers I upon the walls so that their ends are supported by the upright timbers II. When these floor timbers have been put in place the friable partitions are broken out of the floor beams I, as described in copending application, Serial No. 632,425, mentioned above and `reenforcements 1 set in place. If desired reenforcing members may also be arranged lengthwise along the walls over the tops of the upright timbers II. These are shown at 33. Whenall reenforcing rods have been set in place the cavities in the timbers II and I which are not to be lled have their openings suitably closed after which concrete may be poured into the channels of the beams I and also into the spaces between the ends of the floor timbers I and over the tops of the wall timbers II, suitable forms in the shape of boards 30 having been first provided so as to retain the concrete in shape along the top of a wall. This filling of concrete will thus provide a series of reenforced Concrete beams 3| bridging from wall to wall and supporting the timbers I. The ends of these beams are connected by means of the concrete iilling along the border 32 with the columns formed by the llings 23. It will be noted that the border 32 provides a re- -enforced concrete beam running along the top of each wall and joining the columns 23. The iioor beams 3l, also of reenforced concrete, are connected at their ends with the columns through these beams along the top of the wall. It will thus be evident that a strong and rigid framework of reenlorced concrete is provided which supports the wall timbers li and the floor timbers l.

While Figure 17 shows a building structure in which the wall is built up of single elements I I, it vill be understood, of course, that the Wall may be constructed as illustrated in Figures 12 and 14 and that such structure is contemplated by this invention. This is illustrated in Figure 18. The same process in general construction applies in either case. The vertical column members 23 of Figures 12 and 14 serve the same purpose as these o Figures 8 and 10 and may be joined by the border members 32. The gaps 22 in this case will be closed before pouring the concrete of the border 32 as described above for the timbers ll which are not to be lled.

Succeeding stories may be built one upon the other byl the same method, each succeeding story serving as a foundation for the one above it.

It will be noted that this invention provides a novel and economical method of building construction. Hollow lithic timbers are provided for both wall and iioor construction. In the wall timbers cavities are provided Within which reenforced concrete columns may be formed. In the iloor timbers suitable cavities are also provided whercin reenforced concrete beams may be cast. Bythemethod of construction described the columns and beams are connected by a reenforced concrete beam along the wall so that a strong and rigid structural frame is provided. The Wall and floor structures are formed by building into this frame the timbers as described herein. 'Ihus a strong and rigid shell is provided which is of the nature of the hollow tile construction so as to provide suitable heat insulating qualities and which also lends itself to the application of various forms of surface dressing for decorative and other purposes.

While this invention has` been described as a unitary system of building construction, it will be obvious that certain features or sub-combinations may be employed without reference to other features or the complete system. It is understood, therefore, that the employment of such individual features or sub-combinations is contcmplated by this invention and is within the scope of the 'appended claims.

lt is obvious that various changes may be made in details of construction without departing from the spirit of this invention; it is, therefore, to l-.v understood that this invention is not to be limited to thespeciflc details shown and described.

Having thus described the invention, what is claimed is:

1. A Wall comprising, a series of precast, homogeneous monolithic, hollow timbers of cast gypsum continuous from floor to ceiling, said timbers being set upright in abutting relation, certain of said timbers being filled with concrete in order to provide supports for the wall, and a connecting structurev incorporated in the Wall joining said supports at the top thereof.

2. A Wall comprising, a series of precast, homogeneous monolithic, hollow timbers of cast gypsum continuous from floor to ceiling, said timbers being set upright in abutting relation, certain of said timbers being lled with concrete in order to provide supports for the wall, and a connecting structure incorporated in the wall joining said supports at the top thereof.

3. A wall comprising, a series of precast, homogeneous monolithic, hollow timbers of cast gypsum continuous from floor to ceiling and having key recesses therein, said timbers being set upright in abutting relation, certain of said timbers being filled with concrete in order to provide supports for the wall, a connecting structure incorporated in the wall joining said supports at the top thereof, and a facing attached to the abutting timbers by securing means engaging said recesses.

4. A wall structure timber of cast gypsum characterized by the features, that it is a homogeneous monolith throughout its structure that it has a length great enough to extend substantially from floor to ceiling, that it has a cavity extending therealong and open at its ends adapted to receive concrete to form a supporting column interlocking with its end supports, and that it has sufficient strength and rigidity to support the concrete in said cavity until it sets.

5. A wall structure timber of cast gypsum characterized by the features, that it is a homogeneous monolith throughout its structure, that it has a length great enough to extend substantially from floor to ceiling, that it has a cavity extending therealong and open at its ends adapted to receive concrete to form a supporting column interlocking with its end supports, that it has sufficient strength and rigidity to support the concrete in said cavity until it sets, and that it is provided at its side with lmeans for interlocking with an adjoining similar timber so as to support the latter.

6. A wall comprising, a double row of upright hollow timbers of cast gypsum positioned in adjoining relation, the cavities in certain of said timbers in each row being filled with concrete to provide supports, said -i'illed timbers being in staggered relation inthe two rows, and a connection structure incorporated in the wall joining said supports at the top thereof.

7. A wall comprising, a'double row of upright 

